Preparation of ortho-alkylated phenols

ABSTRACT

This invention is for a shaped, alkylation catalyst comprising magnesium oxide bonded with an inert, organic polymeric binder and to the use of the catalyst in a proces for the orthoalkylation of phenols. The process comprises the vapor phase reaction of a non-ortho-substituted phenol with an alcohol in the presence of the catalyst. The catalyst of the invention is an improvement over prior art catalysts used for ortho-alkylation of phenols as it substantially reduces the induction period for maximum reaction selectivity, eliminates loss of catalyst arising with use of powders and substantially extends catalyst life.

United States Patent S Van Sorge PREPARATION OF ORTHO-ALKYLATED PHENOLS [75] Inventor: Bernardus J. Van Sorge, Selkirk,

[73] Assignee: General Electric Company,

Pittsfield, Mass.

[22] Filed: Aug. 1, 1969 [21] Appl. No.: 846,925

FOREIGN PATENTS OR APPLICATIONS 717.588 l0/l954 Great Britain 260/621 R Oct. 22, 1974 Primary Examiner-Bernard Helfin Assistant Examiner-Norman P. Morgenstern Attorney, Agent, or Firm-Morgan, Finnegan, Durham & Pine 5 7 ABSTRACT This invention is for a shaped, alkylation catalyst comprising magnesium oxide bonded with an inert, organic polymeric binder and to the use of the catalyst in a proces for the ortho-alkylation of phenols. The process comprises the vapor phase reaction of a nonortho-substituted phenol with an alcohol in the presence of the catalyst. The catalyst of the invention is an improvement over prior art catalysts used for orthoalkylation of phenols as it substantially reduces the induction period for maximum reaction selectivity, elim-. inates loss of catalyst arising with use of powders and substantially extends catalyst life.

7 Claims, N0 Drawings PREPARATION OF ORTHO-ALKYLATED PI-IENOLS BACKGROUND OF THE INVENTION 1. Introduction This invention relates to the ortho-alkylation of phenols, and more particularly, to the vapor-phase orthoalkylation of phenols by reaction of a non-orthoalkylated phenol with an alcohol in the presence of a shaped catalyst comprising magnesium oxide bonded with an inert, organic polymeric binder. I

2. Description of the Prior Art In commonly assigned Hamilton US. Pat. application Ser. No. 371,189, filed May 29, 1964, now US Pat. No. 3,446,856, there is disclosed and claimed a method for methylating the ortho positions of phenol by the vapor phase reaction of a phenol with methanol in the presence of magnesium oxide as a catalyst at a catalyst bed temperature in the range of 475 to 600 C. Under the conditions described in the Hamilton application, phenol is selectively ortho-methylated in yields in excess of 95 percent. Thus, the reaction offersa means for economically converting phenol to ortho-cresol, a useful disinfectant and wood preservative, and for converting both phenol and ortho-cresol to 2,6-xylenol, a monomer which can be polymerized to form poly-2,6- xylenol, a higher performance thermoplastic material.

While the Hamilton invention provides an economic synthesis for both 2,6xylenol and ortho-cresol from phenol, the service life of the magnesium oxide catalyst is relatively short due to the high temperature at which the reaction is required to take place, i.e. about 90 to 100 hours service life at the typical reaction temperature of about 530C. Also the magnesium oxide catalyst of the Hamilton application is only moderately selective with respect to methanol, with methanol selectivity being in the range of about 40 to 50 percent. This means that more than about two moles of methanol are required for each mole of phenol entering into reaction with the methanol. In addition, use of unmodified magnesium oxide in powdered form results in a rather large induction period for maximum selectivity. The term induction period may be defined as the period from the time of starting the reaction to the time at which the catalyst reaches and maintains maximum orthoalkylation selectivity. Finally, the use of magnesium oxide in powdered or sintered form provides processing difficulties.

STATEMENT OF THE INVENTION The present invention is predicated upon the discovery that if the ortho-alkylation catalyst consists of magnesium oxide bonded with an inert, organic polymeric binder, the alkylation reaction will proceed with a high degree of both methanol and phenol selectivity and the induction period for maximum selectivity is substantially reduced. Moreover, the catalyst may be molded to a desired shape and will have strength properties that will prevent particles of the catalyst from breaking or flaking off in operation or handling thereby. substantially extending the service life of the catalyst with a minimum of loss during operation. In addition, the reaction temperature may be reduced thereby improving the overall economy of the process.

Accordingly, the present invention has as one object, the provision of a catalyst which will enable orthoalkylation of phenol to be carried out with a high degree of selectivity and high yield.

Another object of the invention is to provide a magnesium. oxide catalyst having excellent physical strength properties which may be molded to a desired shape and which will have a service life of many hundreds of hours before needing regeneration or other treatment.

Still another object is to provide a process for formation of ortho-alkylated phenols in high yield.

DESCRIPTION OF THE PREFERRED EMBODIMENTS In one aspect, the ortho-alkylation catalyst of the invention is provided by blending finely divided magnesium oxide powders with finely divided polymer powders or by wetting the magnesium 'oxide powder with a solution of the polymer in a suitable solvent. Where polymer powders are used, both the polymer powders and magnesium oxide powders are preferably maintained below an average particle size of 500 microns in diameter. The percentage of polymer in the blend is preferably maintained low and may be as little as l per cent by weight or as high as 15 percent or more. The preferred range varies from 2 to 6 percent by weight. After the powders are blended together, water is added to the blend inan amount sufficient to completely wet the blend so that it may be molded to shape. Typically, one part by weight water is added for each part of the powder blend. The blend is then molded to shape under pressure and dried at about 200 F. and subsequently calcined at an elevated temperature. The calcination temperature should be below that temperature which causes a visible degradation of the polymer binder and should be maintained at this temperature for a time sufficient to dry the catalyst. In general, a calcination temperature of between 300 and'500F. fora time up to about 3 hours is sufficient. As water is evaporated from the catalyst, minute pores form thereby exposing the magnesium oxide and making the catalyst active. A surface area of at least 20, and preferably from to 200 square meters per gram of catalyst is desirable. The shape of the catalyst may be in the form of Raschig rings, cylinders, tablets or any other shape known to the art.

The polymeric binder is not critical provided it is inert to the reactants, is not affected by the solvents in the reaction system and is capable of withstanding the elevated temperatures of the reaction, though some coking of the binder is permissible and may even be desirable. The cellul osic molding compounds such as cellulose acetate, cellulose propionate and cellulose acetate butyrate are preferred. Other polymers that are suitable, but less preferred include the acetyl resins, the

is equivalent to the process disclosed in the abovenoted Hamilton patent application Ser. No. 371,189 and differs therefrom by the substitution of the catalyst of this invention.

While the invention has been described as applying specifically to phenol and ortho-cresol, it applies in general to phenols having an ortho-hydrogen. For example, it also applies to ortho-phenyl phenol, orthoethyl phenol, and to phenols in which there are alkyl and aryl groups in the meta and para positions. These phenols may be represented by the formula in which each R is a monovalent substituent selected from the group consisting of hydrogen, alkyl, phenyl, and alkyl-substituted phenyl.

The magnesium oxide used as catalyst in conjunction with the inert plastic binder is a material having a very high surface to weight ratio. Magnesium oxides having the desired porosity may be prepared by thermally decomposing magnesium carbonate, basic magnesium carbonate, and magnesium hydroxide as these materials may be converted to magnesium oxide without fusing or sintering.

. In carrying out an alkylation in accordance with this invention, any one or a mixture of phenols having an orthohydrogen may be vaporized and passed through a reactor heated to a temperature of at least 460 C. containing the magnesium oxide catalyst of the invention. in order to obtain the maximum yield or orthoalkylated products, at least one mole of an alkyl alcohol and preferably from one to three moles of the alcohol is used for each ortho position in the phenol to be alkylated. Forv example, if phenol which has 2-orthohydrogens per molecule is to be methylated to produce a maximum yield of 2,6-xyleno1, it is desirable to use two to six moles of methanol for each mole of phenol with higher yields being obtained with the higher ratios of methanol to phenol.

The vapors issuing from the reactor are condensed and the products separated by conventional methods such as crystallization, distillation, etc. The reaction proceeds at atmospheric pressure, but it is obvious that pressures above or below may be used.

The selectivity favoring ortho-alkylation over meta or para alkylation under steady state condition, is substantially the same for the magnesium oxide catalyst of the invention as for pure magnesium oxide. One advantage to operating with the catalyst of this inventionlies in the fact that the life of the catalyst is extended considerably before regeneration or other treatment is needed. Catalysts made according to this invention have operated without reduction in catalytic activity for periods in excess of 500 hours.

An additional major benefit accruing to the magnesium oxide catalyst of the invention lies in the reduction of the inductionperiod that .is encountered with other magnesium oxidecatalysts. As noted above, the induction period is the time necessary for a catalyst to reach maximum selectivity for ortho-alkylation. During this induction period, the prior art catalysts usually produce a relatively large amount of byproducts such as 2,4,6-mesitol and the like. The catalyst of the subject invention results in a molar phenol selectivity reaching a level of over 95 percent and a molar methanol selectivity in excess of 65 percent in approximately 6 hours at a temperature of about 480 C. as compared to about 24 hours and more for catalysts of the prior art.

In the following Example 1, the system consisted of a reservoir containinig a solution of methanol and phenol connected to a metering pump which fed the reactants through a 1 inch stainless steel tube into a vertical vaporizer made from a 12-inch long piece of 1 inch O.D., 0.8 inch [.D. stainless steel tubing. The vaporizer was partially immersed in a bath of fused salt to a depth of about 6 inches. The vapors from the reactor were fed to a 0.8 inch 1.1). stainless steel tube reactor through a 1 inch length of inch 1.D. stainless steel pipe located 5 /2 inches above the bottom of the vaporizer and connected to the reactor 13 inches from its bottom. The reactor was 24 inches long and was immersed in the fused salt bath to a depth of 14 inches. Since the inlet tube of the reactor coming from the vaporizer also passed through the fused salt bath, it served as a preheater for the vapor issuing from the vaporizer to bring the vapor up to the temperature of the reactor. The reactor was equipped with a thermowell made from /2 inch stainless steel tubing concentrically located in the reactor and extending downward into the catalyst bed. to a depth of l to 6 inches. Thus, the catalyst bed temperature could be measured throughout a large section of the tube. The reactor tube was filled with a constant volume of 100 milliliters of catalyst which filled the tube to a depth of about 12 inches. Thus the vapors were-fed to the top of the catalyst bed in the reactor and product vapors left the reactor through a inch O.D. stainless steel tube connected to the bottom of the reactor. The product vapors from the reactor were led to a water-cooled condenser and receiver.

The catalyst used was prepared by blending 200 grams of commercial magnesium oxide catalyst with about 10 grams of Avicel polymer, a cellulosic polymer available from the FMC company and about 200 grams of water. The blend was molded into cylindrically shaped pellets having a diameter and length of 3/16 inch. The catalyst was dried at 200F. and calcined by heating to further dryness at about 450 F. for about 3 hours. The catalyst was then placed in a reaction chamber which was maintained at a temperature of 480 C. The feed composition was vaporized and the vapors passed through the catalyst chamber. The conditions "LHSV is the liquid hourly space velocity and defines the volume of liquid per volume of Catalyst pcr houi'.

From the above table, it can be seen that the alkylation which took place was primarily occurring in the ortho-position. The ortho-cresol formed in the reaction and unreacted phenol may be recycled if desired. By increasing the liquid hourly spaced velocity, the ratio of ortho-cresol to 2,6-xylenol may be substantially increased. For example, using substantially the same reaction conditions, an increase in the liquid hourly space velocity to 3.47 hr. would result in a phenolic distribution comprising about 42.7 percent unreacted phenol, 36.2 percent ortho-cresol, 20.2 percent 2,6- xylenol, and about 0.8 percent 2,4,6-mesitol.

In the following Examples 2 and 3, the procedure of Example 1 is repeated. ln Example 2, the catalyst used was substantially the same as that of Example 1. ln Example 3, the catalyst used was prepared by pelletizing and calcining substantially pure powders of magnesium oxide at a temperature of about 500 F. The conditions and results are indicated in the following Table II:

presence of an alkylation catalyst of an alkyl alcohol and a phenol having the general formula:

l5 substituted phenyl; the improvement comprising performing the reaction in the presence of a porous catalyst that is a magnesium oxide powder bonded with The molar phenol selectivity is defined as the ratio of phenol converted to 2.6-xylenol to phenol converted to Lb-xylcnol and hy-produets multiplied by I00. The amount of phenol converted to orthwcresol is not included in the definition as it is recycled in the feed stream if desired.

' The molar methanol selectivity is defined as the ratio of methanol reacted to form lfmqlenol to the methanol reacted to form ltvxylenol and other byproducts multiplied hy H10. The amount of methanol converted to ortho-cresol is not included in the definition as it is reeycletl in the I'eed stream ildesired.

From the above Table, it can be seen that the induc tion period for the reaction using the catalyst of this invention is substantially shorter than that for the prior 40 art magnesium oxide catalyst. Moreover, methanol selectivity is substantially improved. A catalyst such as that of Example 2 would have a total life of 500 hours or more while that of Example 3 would have a total life of less than 100 hours.

While the foregoing discloses certain specific embodiments of the invention, it is understood that there are many modifications which obviously fall within the proper scope of the invention. Accordingly, the invention is intended to be limited in scope only as may be necessitated by the scope of the appended claims.

I claim:

1. In a process for alkylating a phenol in the ortho position which comprises the vapor phase reaction in the from l-l 5 percent by weight aria"iitrfagfitbEatfi losic polymeric binder.

2. The process of claim 1 where the alcohol is methyl alcohol. I 3. The process of claim 2 where the catalyst bed temperature is maintained at a temperature of at least 460 C 4. The process of claim 2, where each R is hydrogen.

5. The process of claim 2 where the phenol is orthocresol.

6. The process of claim 2 where the phenol is a mixture of unsubstituted phenol and ortho-cresol.

7. The process of claim 1 where the polymeric binder Y comprises from 2 to 6 percent by weight of the total catalyst. 

1. IN A PROCESS FOR ALKYLATING A PHENOL IN THE ORTHO POSITION WHICH COMPRISES THE VAPOR PHASE REACTION IN THE PRESENCE OF AN ALKYLATION CATALYST OF AN ALKYL ALCOHOL AND A PHENOL HAVING THE GENERAL FORMULA:
 2. The process of claim 1 where the alcohol is methyl alcohol.
 3. The process of claim 2 where the catalyst bed temperature is maintained at a temperature of at least 460* C.
 4. The process of claim 2, where each R is hydrogen.
 5. The process of claim 2 where the phenol is ortho-cresol.
 6. The process of claim 2 where the phenol is a mixture of unsubstituted phenol and ortho-cresol.
 7. The process of claim 1 where the polymeric binder comprises from 2 to 6 percent by weight of the total catalyst. 